Pressure seal license plate decal

ABSTRACT

A license plate decal is provided on a folded (e.g. Z-folded) business form which acts as a carrier for the decal. A cut out is formed in a panel of the mailer and a patch (such as a glassine patch) is adhesively secured at a peripheral portion to the mailer panel and a release coating is provided on at least a significant part of the central portion of the patch. The decal adhesive engages the release coating so that the decal and its associated pressure sensitive adhesive may be readily removed from the patch. The patch may be secured to the paper on either face thereof; if secured at the bottom face, the patch and decal can flex into the cutout to provide a minimum thickness when in a stack of mailer intermediates. Where the patch is secured at its top face, the maximum thickness of the patch and decal combination is preferably about 0.008 inches, which is significantly less than the thickness at the decal in prior art carriers.

BACKGROUND AND SUMMARY OF THE INVENTION

There are many situations where it is desirable to forward a decal, bymail, to a recipient. The decal may be removed from the mailing pieceand applied to any appropriate item, such as a membership card, avehicle window, or a license plate. When such mailers are being printed(such as with the outgoing address) for mailing, they typically arestacked in a printer tray. In conventional constructions of the carrierswhich ultimately form the mailers the bulge provided in the area of thedecal is greater than desirable typically because the decal laminate isthick. In conventional constructions the thickness at the laminate istypically between about 0.011 inches and 0.0135 inches. This limits thenumber of sheets that can be stacked in the tray for processing, and inextreme situations may adversely affect feeding of the sheets.

According to the present invention a decal carrier in general, and amailer type business form intermediate and mailer produced from theintermediate, are provided which facilitate the stacking of more sheetsin a printer tray by reducing the thickness of the decal laminatecompared to the prior art. The thickness at the decal laminate accordingto the invention is a maximum of 0.010 inches, and typically is onlyabout 0.008 inches. This not only allows more sheets to be stacked inthe printing tray and minimizes the possibility of problems in feedingthe sheets to a printer, it makes the ultimate mailing piece thinner andalso provides for enhanced utility in handling the decal by therecipient.

The advantageous results are achieved according to the present inventionprimarily by providing a release coating (such as a silicone coating)directly on a patch which covers a cut out in the carrier for the decal.This allows the decal to be applied directly to the patch, without anintermediate release liner as is common in the prior art. Also therelease coating may be provided over substantially the entire face ofthe patch, with a special adhesive used to attach the patch to thecarrier.

Alternatively the advantageous results according to the invention may beobtained by securing the bottom face of the patch to the top face of theintermediate/carrier. This means that when the carrier/intermediate isprovided in a stack (such as in a printer), the decal and patch flexinto the cutout so that the effective thickness of the patch and decalmounted thereon is substantially the same as the combined thickness ofthe carrier/intermediate, first adhesive, and patch adjacent the cutout.

According to one aspect of the present invention a decal carrier, ingeneral, is provided. The carrier has the following components: A sheetof paper having first and second faces. A cutout formed in the sheet ofpaper. A patch having first and second faces, a central areaapproximately the size of the cutout, and a peripheral area surroundingthe central area. A release coating provided on the first face of atleast a significant part (at least the size and shape of the decaladhesive which will be placed over it) of the central area of the patch.A first pressure sensitive adhesive disposed between the peripheral areaof the patch and one face of the sheet of paper and holding the patch tothe sheet of paper. A decal having first and second faces. Indiciaassociated with the decal. And, a second, permanent, pressure sensitiveadhesive associated with the decal second face, the second adhesiveengaging the release coating on the patch, and removable from the patchwith the decal. The first pressure sensitive adhesive may be disposedbetween the peripheral area of the patch first face and the second faceof the sheet of paper, in which case the patch and decal mounted thereonhave a thickness which is a maximum of 0.010 inches (typically about0.008 inches), or the first adhesive is disposed between the patchsecond face and the first face of the sheet of paper, allowing theflexing of the decal and patch into the cutout, as described above.

The indicia may be motor vehicle license plate indicia and the indiciamay be associated with the decal first face, the decal comprising alicense plate decal. However instead the decal may have a reflectivematerial first face, or the indicia may be provided on the second face(such as where the decal is to be applied the inside of a vehiclewindow), underneath the second adhesive.

In one construction, especially when the first adhesive is between thepatch first face and paper sheet second face, the release coating may bea spot coating on the central area of the patch so that the peripheralarea of the first face of the patch is substantially devoid of releasecoating. The first adhesive preferably is permanent adhesive,permanently connecting the patch peripheral area to the paper sheet; itmay be repositional adhesive only if the patch doesn't detach and causeprinter problems. The release coating may be any suitable releasecoating, but typically is a conventional silicone release coating. Thepatch may be of any suitable material and need not be opaque ortranslucent, but desirably is of the same material as a conventionalwindow patch in a mailer or envelope (e.g. glassine).

According to another aspect of the present invention a mailer typebusiness form intermediate is provided. The intermediate comprises thefollowing components: A quadrate paper sheet having top, bottom, andside edges, and first and second faces, the top and bottom edgessubstantially parallel to each other and the side edges substantiallyparallel to each other. First and second fold lines substantiallyparallel to the top and bottom edges and dividing the sheet into first,second and third panels, the first panel between the top edge and thefirst fold line, and the second panel between the first and second foldlines. The first and second panels each having a first length along theside edges, and the third panel having a second length along the sideedges (e.g. which is less than the first length). A cutout in the secondpanel. A patch having first and second faces, a central areaapproximately the size of the cutout, and a peripheral area surroundingthe central area. A release coating provided on the first face of atleast the majority of the central area of the patch. A first pressuresensitive adhesive disposed between the peripheral area of the patch andone of the faces of the second panel and holding the patch to the secondpanel. A decal having first and second faces. Indicia associated with atleast one of the decal faces. And, a second, permanent, pressuresensitive adhesive associated with the decal second face, the secondadhesive engaging the release coating on the patch, and removable fromthe patch with the decal.

Outgoing address indicia may be provided on the third panel first face,and adhesive means (such as a plurality of patterns of pressureactivated cohesive such as described in U.S. Pat. Nos. 4,918,128 and5,201,464 (the disclosures of which are hereby incorporated by referenceherein)). The adhesive means hold the intermediate in a mailerconfiguration when the paper sheet is folded (e.g. Z-folded) about thefirst and second fold lines to form a mailer having a second panelsandwiched between the first and third panels and the first face of thethird panel forming an outside face of the mailer, and the decal andpatch covered by the first and third panels. The details of the decaland patch, and where the first adhesive is provided, may be as describedabove.

According to another aspect of the present invention a mailer typebusiness form is provided. The mailer type business form comprises thefollowing components: A first solid paper panel. A second paper panelhaving a cutout therein and first and second faces. A third solid paperpanel. The second panel sandwiched between the first and second panelsso that the cutout is covered by the first and second panels. Adhesivemeans for holding the panels to each other with the second panelsandwiched between the first and second panels. A patch having first andsecond faces, a central area approximately the size of the cutout, and aperipheral area surrounding the central area. A release coating providedon the first face of at least the majority of the central area of thepatch. A first pressure sensitive adhesive disposed between theperipheral area of the patch and one of the faces of the second paneland holding the patch to the second panel. A decal having first andsecond faces. Indicia associated with at least one of the decal faces.And, a second, permanent, pressure sensitive adhesive associated withthe decal second face, the second adhesive engaging the release coatingon the patch, and removal from the patch with the decal. The details ofthe patch and decal, and positioning of the first adhesive, may be asdescribed above, and other panels may also be provided.

In the use of the mailer type business form as described above, wherethe decal comprises a license plate decal, or vehicle sticker, thefollowing sequential steps may be employed: (a) Opening the businessform to expose the second panel and patch. (b) Transporting the patch tothe vicinity of a motor vehicle having a license plate or windshield.(c) Removing the decal from the patch. And, (d) pressing the secondpressure sensitive adhesive of the decal to the license plate orwindshield so that the decal is adhesively attached to the license plateor windshield with the decal license plate or registration indiciavisible from exterior the vehicle. When the decal is a vehicleregistration decal, or the like, it is applied to the interior of awindow of a motor vehicle, and in that case the indicia is typically onthe decal second face underneath the second adhesive.

It is the primary object of the present invention to provide a simple,effective, and advantageous decal carrier in general, as well as amailer type business form intermediate and a mailer per se whichtransport a decal. This and other objects of the invention will becomeclear from an inspection of the detailed description of the inventionand from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 side schematic detail views of conventional prior artlicense plate decal carriers;

FIGS. 3 and 4 are views like those of FIGS. 1 and 2 but showingexemplary carriers according to the present invention;

FIG. 5 is a top plan view of the carrier of FIG. 4 in the form of amailer type business form intermediate;

FIG. 6 is a bottom plan view of the intermediate of FIG. 5;

FIG. 7 is a top perspective view showing the intermediate of FIGS. 5 and6 being folded into a mailer type business form according to the presentinvention;

FIG. 8 shows the patch and decal associated with the mailer of FIG. 7after they have been detached therefrom;

FIG. 9 is a schematic detail representation showing the application ofthe decal of FIG. 8 onto a license plate;

FIG. 10 is a view like that of FIG. 3 only showing another embodiment ofan exemplary carrier according to the present invention; and

FIG. 11 is a view of the carrier of FIG. 10 shown in a stack of carriersso that the decal and patch flex into the cutout formed in the carrierpaper sheet.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one conventional prior art construction for a carrierfor a license plate decal (of the type that typically provides therenewal year on a license plate, such as used by many states in theUnited States). The carrier construction 10 includes a sheet of paper 11having a conventional release liner 12 attached thereto by adhesive 13.On top of the release liner 12 is the decal 14 with permanent pressuresensitive adhesive 15 engaging the release liner 12. The thickness D ofthis construction is about 0.0135 inches, which provides a significantenough bulge so that if in a paper tray of a printer the number ofsheets in the tray is significantly limited, and under extremecircumstances sheet feeding problems may occur. The carrier sheet 11,after printing (such as address information, and perhaps vehicleregistration information) is mailed to the license plate owner, whoopens the mailer, removes the decal 14 and associated adhesive 15 fromthe release liner 12 and the sheet 11, and then applies the adhesive 15to the appropriate place on the license plate so that the decal 14 ispermanently affixed to the license plate. Indicia on the decal 14typically includes the renewal year (e.g. "99" for the year 1999 as thenext renewal date).

Another prior art construction is illustrated in FIG. 2 at 17. Thisconstruction has a thickness D1 at the decal 14 which is somewhat lessthan that of the FIG. 1 construction, e.g. D1 being on the order ofabout 0.011 inches. In the construction of FIG. 2 the decal 14 withadhesive 15 and the release liner 12 with adhesive 13 are the same as inthe FIG. 1 construction. However the construction 17 of FIG. 2 uses apaper carrier sheet 18 with a cutout 19 therein, and a patch 20 (such asof a conventional window patch material, such as glassine) is adhered byadhesive 21 to the bottom of the sheet 18. Since the patch 20 has athickness less than that of the sheet 18, the dimension D1 is slightlyless, but still not acceptable for many circumstances. Also in both theFIGS. 1 and 2 constructions recycling of the sheet 11, 18 is difficultbecause the release liner 12 and--in the case of the FIG. 2construction--the glassine patch 20 are adhered to the rest of the sheet11, 18.

According to the present invention the drawbacks associated with theprior art constructions of FIGS. 1 and 2 are significantly reduced oreliminated. Different major embodiments according to the presentinvention may be provided, the embodiments of FIGS. 3, 4, or 10. In theembodiments of FIGS. 3, 4, or 10 components having the same constructionas those in the prior art configurations of FIGS. 1 and 2 are shown bythe same reference numeral.

In the FIG. 3 embodiment 24 the major difference compared to the FIG. 2prior art construction is that a spot coating 25 of adhesive releasematerial (such as silicone, or any other conventional adhesive releasematerial) is provided on that portion of the top face of the patch 20within the cutout 19. The patch 20 is still affixed to the bottom face18" of the carrier 18 paper sheet by the adhesive 21. The decal 14 isslightly above the top surface 18' of the carrier sheet 18. Thisconstruction eliminates the thickness of the release liner 12, so thatthe thickness D2 is 0.010 inches or less, typically about 0.008 inches.This makes a significant difference in the number of sheets that can bestacked in a printer tray, and in minimizing feeding problems.

The adhesive 21 preferably is any suitable conventional permanentpressure sensitive adhesive for holding a patch to a paper sheet. Theadhesive 21 may be repositional adhesive, such as that available fromMoore U.S.A. of Lake Forest, Ill. under the trademark "CLEANTAC", or thedifferent type of repositional adhesive used in the "POST-IT" productsavailable from 3M of Minneapolis, Minn., only if the environment of useis such that the patch 20 will not detach during handling (e.g. whenpassed through a laser or impact printer). If repositional adhesive canproperly be provided as the adhesive 21, and does not permanently fuseduring passage through a laser printer, then the entire patch 20 can beremoved from the carrier 18, so that the carrier 18 may be recycled moreeasily, and also the user need only carry the patch 20 with decal 14thereon to a vehicle location to apply the decal 14.

FIG. 4 illustrates another embodiment according to the presentinvention. In the FIG. 4 embodiment, 27 instead of a spot coating ofrelease material like the coating 25 covering at least a majority of thecentral portion of the patch 20, an adhesive release coating 29 isprovided which covers substantially the entire top face of the patch 28,including the periphery thereof. A suitable conventional aggressiveadhesive 30 holds the patch 28 to the carrier 18, that is one capable ofbonding even to silicone, or like, release coatings.

In the practice of the present invention the patches 20, 28 may beglassine or other translucent or transparent material, but need notnecessarily be so because they typically will be provided on an interiorof a mailer and therefore may be an opaque material. However the patch28, 20 material should have a smaller thickness than the sheet 18 sothat the thickness D2 is 0.010 inches or less, preferably about 0.008inches.

The FIG. 3 embodiment is illustrated in association with a mailerintermediate in FIGS. 5 through 7. In FIG. 5 (as well as in FIGS. 8 and9) one can see the license plate indicia 31, 31' which typically isprovided on the top face of the decal 14 (opposite the face to which theadhesive 15 is applied). The indicia 31 in this embodiment includeslicense plate year of renewal indicia, while the indicia 31' mayindicate the registering state or other registration information, or anyother suitable indicia.

While a carrier per se may be provided according to the invention (whichmay merely be inserted into a conventional envelope), preferably thecarrier sheet 18 is part of an intermediate 32 of a mailer type businessform, as seen in FIGS. 5 through 7. The intermediate 32 is formed by thepaper carrier sheet 18 which has quadrate configuration including topand bottom substantially parallel edges 33, 34, and substantiallyparallel side edges 35, 36. As seen in FIG. 5 preferably tractor drivestrips 37, having tractor drive holes 38, are typically provided as partof the intermediate 32 during construction thereof, but the tractordrive strips 37 are slit off--at the side edges 35, 36--duringprocessing by conventional slitters. This slitting is typicallyaccomplished before the intermediate 32 is sent to the motor vehicleregistration organization, or like entity which will be processing theintermediates 32 and sending them out in the mail, although the slittingmay alternatively be accomplished at the final printing and mailingsite.

The intermediate 32 is typically divided into panels by first and secondfold lines 39, 40, respectively, which are substantially parallel to theedges 33, 34. The fold lines 39, 40 may be score lines, perforationlines, or any other suitable lines which facilitate folding (and perhapsdetachment). The intermediate 32 also preferably includes perforationlines (or like lines of weakness) 41, 42 which are parallel to the sideedges 35, 36.

The fold lines 39, 40 define the intermediate 32 into three panels, thefirst panel 43 between the edge 33 and the first fold line 39, a secondpanel 44 between the fold lines 39, 40, and a third panel 45 between thesecond fold line 40 and bottom edge 34. The fold lines 39, 40 in theembodiment illustrated in FIGS. 5 through 7 facilitate Z-folding of theintermediate 32, but alternatively the intermediate 32 could beconstructed for C-folding, or other fold lines and panels could beprovided so that other panel configurations are utilized. In theembodiment specifically illustrated in FIGS. 5 through 7 the length ofthe first and second panels 43, 44 along with side edges 35, 36 are thesame, whereas the length of the third panel 45 along with side edges 35,36 is--in the embodiment illustrated--significantly less than that ofthe first and second panels 43, 44 (although other embodiments withequal length panels may be provided). For example the first panels 43,44 may have a length of four inches each, while the third panel 45 has alength of three inches, whereas the width of the entire intermediate 32is 81/2 inches, so that the intermediate 32 is made from a conventional81/2×11 inch sheet. The eccentric construction illustrated allows moredata to be printed on the interior faces of the panel, particularly theface 18' of the panels 43, 44 illustrated in FIG. 5, for a given sheetsize, while still obscuring the decal assembly 27 during mailing.

Various indicia may be applied to the face 18' as illustrated in FIG. 5.For example outgoing address indicia 46 and return address indicia 47.The indicia 46, 47 typically would be printed at the mailing location.Indicia 48 may also be provided as instructions on how the ultimatemailer formed from the intermediate 32 may be opened.

Adhesive means are provided for holding the intermediate in the form ofa mailer after folding (e.g. Z-folding about the fold lines 39, 40 (seeFIG. 7). The adhesive means may comprise any suitable adhesive disposedin any particular manner on the sheet 18. For example rewettable, heatactivated, or standard pressure sensitive adhesive could be used, and itmay be disposed in the form of discreet pattern elements such as dots,lines, or other shapes, or continuous strips. In the preferredembodiment the adhesive means comprises a pressure activated cohesivesuch as a styrene-natural rubber copolymer, as in U.S. Pat. No.4,918,128. The pressure sensitive cohesive, in various trade availableforms thereof, and patents showing the same, are disclosed in U.S. Pat.No. 5,201,464 (the disclosure of which is incorporated by referenceherein).

While a wide variety of different patterns of the pressure sensitivecohesive may be provided, typical forms are illustrated at referencenumerals 49 through 56 in FIG. 5 and by reference numerals 65-68 in FIG.6. The strips 49 are adjacent the edge 33 and cooperate with the strips50 adjacent the fold line 40 when the intermediate 32 is folded aboutthe fold line 39, while the strips 51, 52 just outside of theperforation lines 41, 42 cooperate with the strips 53, 54 of the secondpanel 44, and the portions of the strips 55, 56 extending across thefold line 39 outside of the perforation lines 41, 42 cooperate with eachother. The adhesive strips 49-56 are activated by passing theintermediate 32 through a pressure sealer which applies a force of about100-200 pounds per inch to the strips 49-56 to effect sealing.

Lines of weakness (such as perforation lines) 58, 59, 60 are preferablyalso provided substantially parallel to the edges 33, 34. Theperforation line 58 allows ready opening of the mailer form from theintermediate 32 since it is disposed between the adhesive strips 49 andthe fold line 39, while the perforation line 59 is similarly disposedbetween the adhesive strips 50 and the fold line 39. The perforationlines 58-60 line up one on top of the other when intermediate 32 isZ-folded about the lines 39, 40, as illustrated in FIG. 7.

Various other indicia may be printed where desired on the intermediate32. For example, further instruction indicia 61 associated with thedecal assembly 27 may be provided on the face 18', and/or like indicia61' (see FIG. 6) on the face 18". Further instruction indicia 62 (seeFIG. 6) for opening up the completed mailer (see FIG. 7) may be providedon the face 18", while descriptive indicia such as about the vehicle orthe registration of the vehicle--as illustrated at 63 in FIG. 5--may beprovided. The face 18' of both panels 43, 44 provides the significantamount of area for printing any indicia desired. The indicia may bepre-printed before the intermediates 32 are sent to the organizationthat will be doing the mailing, or may be applied by a printer at thesame time that the outgoing address 46, and the like, are applied.

The pressure cohesive strips 65-68 illustrated in FIG. 6 hold the panels44, 45 together when the mailer is formed by folding (e.g. Z-folding,see FIG. 7), and the adhesive action of the strips 65-68 is activated atthe same time as for the strips 49-56 by passing through conventionalequipment for that purpose. The strips 65, 66 cooperate with each otherwhen the intermediate 32 is Z-folded about the line 40, while theportions of the strips 67, 68 on the opposite sides of the fold line 40cooperate with each other.

When the final mailer is formed, the second panel 44 is sandwichedbetween the first and third panels 43, 45, and the decal assembly 27 isnot visible, being covered up by both the panels 43, 45. The adhesivestrips 49-56 and 65-68 maintain the integrity of the mailer duringsubsequent mailing and other handling.

After the intermediate 32 is Z-folded into a mailer configuration, asillustrated in FIG. 7, it is passed through the conventional pressuresealing equipment, postage is applied (if not applied by printingearlier, such as a permanent number), and then the mailer is sent to theoutgoing addressee indicated by the address 46. When the addresseereceives the mailer of FIG. 7, he or she opens the mailer by followingthe instructions 62, that is by separation along the perforation lines41, 42, and 58 through 60. This results in a sheet comprising merely thepanel 43, 44 with the patch 28 still attached as illustrated in FIGS. 4through 7. To facilitate recycling of that sheet and also to makeutilization of the decal 14 simpler, the user (such as by following theinstructions 61, 61') detaches the entire patch 28 from the panel 44,the adhesive 30 releasing. The detached patch 28 with decal 14 thereonis seen in FIG. 8. The decal 14 is then removed simply by peeling it offthe release coating 29--as illustrated by arrow 69 in FIG. 8--and thenthe decal 14 is ready to be applied to a license plate 70 or windshieldof a motor vehicle or the like.

As illustrated in FIG. 9, the license plate 70 has a conventionallicense plate indicia 71 (typically either a unique identifying number,or a personalized license plate) and has a portion 72 thereof within themounting frame 73 for the year of renewal decal 14 to be applied. Themounting frame 73 is attached to the motor vehicle 74 or the like. Theadhesive 15 on the back of the decal 14 adheres to the metal plate 70 atthe area 72, or to any previous decal that may be thereon. If decal 14is a vehicle registration sticker (e.g. "county tag"), it may be appliedto the inside of a windshield, the indicia visible through adhesive 15.

While the invention has been primarily described with respect to alicense plate decal, it should be understood that any type of decal maybe provided according to the invention, and any number of decals in aparticular mailer. For example, two cutouts 19 and associated decalassemblies 24 may be provided associated with the panel 44 (one for eachlicense plate), or a single larger cutout in which two decals 14 areprovided on the same patch 20 with silicone coating spots 25, or alarger sheet can be used for the intermediate 32 with more folds andpanels and any other number of decals may be mounted. Also, the decals14 may have reflective surfaces, or can have other types of indiciabesides license plate indicia, such as membership renewal indicia to puton a membership card or plaque or certificate, or any of a wide varietyof other indicia. Instead of the indicia--such as the indicia 31 beingprovided on the opposite face of the decal 14 from the adhesive 15, orthe decal 14 is designed to be applied to the inside of a window (of adwelling or a motor vehicle) the indicia can be on the face of the decal14 containing the adhesive 15 (or indicia can be provided on bothfaces), and visible through the adhesive 15.

FIG. 10 shows another exemplary decal assembly 70 according to thepresent invention. In FIG. 10 components that are identical to those inFIG. 4 are shown by the same reference numeral. The major differencebetween the assembly 70 of FIG. 10 and the assembly 27 of FIG. 4 is thatthe first pressure sensitive adhesive 121 (preferably a permanentadhesive) is applied to the bottom face of the patch 28, and the topface 18' of the sheet 18, so that even if the silicone coating 29 isprovided over the entire top face of the patch 28 (as illustrated inFIG. 10, although the silicone coating 29 may be provided as aspot--like the spot 25 in FIG. 3) the adhesive 121 does not engage asilicone coating, but only the actual material (such as glassine) of thepatch 28. In this way a wider variety of conventional adhesives may beused as the adhesive 121 (any suitable conventional pressure sensitiveadhesive for holding patches to window envelopes).

The effect of the construction in FIG. 10 is not to provide a thickerpatch, such as in the FIG. 1 prior art construction, even though thethickness of the assembly 70 at the decal 14 when in the position inFIG. 10 is not much different than the distance D in the FIG. 1 priorart construction. However because of the positioning of the flexiblepatch 28 with respect to the cutout, and the dimensions of the decal 14with respect to the cutout 19 (which are substantially the same as isillustrated for the decal 14 in FIGS. 5 through 7, except that at thelower and upper edges of the decal 14 as seen in FIGS. 5 and 6 thespacing will be somewhat greater to the cutout 19 than illustratedtherein in order to allow complete flexure as will be described withrespect to FIG. 11) so that when the sheet 18 is in a stack with othersheets 18 18 (such as in a printer), the patch 28 and decal 14 flex intothe cutout 19 and the effective thickness D3 (see FIG. 11) of theassembly 70 is substantially the same as the combined thickness of thepaper sheet 18, first adhesive 121, and patch 28 adjacent the cutout 19.FIG. 11 schematically illustrates this flexure of the decal 14 and patch28 into the cutout 19 when a plurality of other sheets 71--allpreferably like the sheet 18--are stacked thereon. The effectivethickness D3 is thus substantially the same as, or slightly less than,the thickness D2 in FIGS. 3 and 4. That is the effective thickness D3may be even less than 0.008 inches.

While the invention has been herein shown and described in what ispresently conceived to be the most practical and preferred embodimentthereof, it will be apparent to those of ordinary skill in the art thatmany modifications may be made thereof within the scope of theinvention, which scope is to be accorded the broadest interpretation ofthe appended claims so as to encompass all equivalent structures andproducts.

What is claimed is:
 1. A mailer type business form intermediatecomprising:a quadrate paper sheet having top, bottom, and side edges,and first and second faces, said top and bottom edges substantiallyparallel to each other and said side edges substantially parallel toeach other; first and second fold lines substantially parallel to saidtop and bottom edges and dividing said sheet into first, second andthird panels, said first panel between said top edge and said first foldline, and said second panel between said first and second fold lines;said first and second panels each having a first length along said sideedges, and said third panel having a second length along said sideedges; a cutout in said second panel; a patch having first and secondfaces, a central area approximately the size of said cutout, and aperipheral area surrounding said central area; a release coatingprovided on said first face of at least a significant part of saidcentral area of said patch; a first pressure sensitive adhesive disposedbetween said peripheral area of said patch and one of said faces of saidsecond panel, and holding said patch to said second panel; a decalhaving first and second faces; indicia associated with at least one ofsaid decal faces; and a second, permanent, pressure sensitive adhesiveassociated with said decal second face, said second adhesive engagingsaid release coating on said patch, and removable from said patch withsaid decal.
 2. A mailer type business form intermediate as recited inclaim 1 wherein said patch and decal mounted thereon have a thickness;and wherein said thickness of said patch and decal is about 0.008inches; and wherein said paper sheet has a thickness which is less thansaid patch and decal mounted thereon thickness.
 3. A mailer typebusiness form intermediate as recited in claim 1 further comprisingoutgoing address indicia on said third panel first face.
 4. A mailertype business form intermediate as recited in claim 3 further comprisingadhesive means for holding said intermediate in a mailer configurationwhen said paper sheet is folded about said first and second fold linesto form a mailer having said second panel sandwiched between said firstand third panels; and said first face of said third panel forming anoutside face of the mailer and said decal and patch covered by saidfirst and third panels, and wherein said second length is less than saidfirst length.
 5. A mailer type business form intermediate as recited inclaim 4 wherein said adhesive means comprises a plurality of patterns ofpressure activated cohesive.
 6. A mailer type business form intermediatecomprising:a quadrate paper sheet having top, bottom, and side edges,and first and second faces, said top and bottom edges substantiallyparallel to each other and said side edges substantially parallel toeach other; first and second fold lines substantially parallel to saidtop and bottom edges and dividing said sheet into first, second andthird panels, said first panel between said top edge and said first foldline, and said second panel between said first and second fold lines;said first and second panels each having a first length along said sideedges, and said third panel having a second length along said sideedges; a cutout in said second panel; a patch having first and secondfaces, a central area approximately the size of said cutout, and aperipheral area surrounding said central area; a release coatingprovided on said first face of at least a significant part of saidcentral area of said patch; a first pressure sensitive adhesive disposedbetween said peripheral area of said patch and one of said faces of saidsecond panel, and holding said patch to said second panel; a decalhaving first and second faces; indicia associated with at least one ofsaid decal faces; a second, permanent, pressure sensitive adhesiveassociated with said decal second face, said second adhesive engagingsaid release coating on said patch, and removable from said patch withsaid decal; and wherein said first adhesive is disposed between saidpatch second face and said first face of said second panel, and whereinsaid patch is flexible and dimensioned with respect to said cutout sothat when in a stack with other intermediates the patch and said decalthereon flex into said cutout and the effective thickness of said patchand decal are thereon is substantially the same as the combinedthickness of said second panel, first adhesive, and patch adjacent saidcutout.
 7. A mailer type business form intermediate as recited in claim6 further comprising outgoing address indicia on said third panel firstface.
 8. A mailer type business form intermediate as recited in claim 7further comprising adhesive means for holding said intermediate in amailer configuration when said paper sheet is folded about said firstand second fold lines to form a mailer having said second panelsandwiched between said first and third panels; and said first face ofsaid third panel forming an outside face of the mailer and said decaland patch covered by said first and third panels, and wherein saidsecond length is less than said first length.
 9. A mailer type businessform intermediate as recited in claim 8 wherein said adhesive meanscomprises a plurality of patterns of pressure activated cohesive.
 10. Amailer type business form intermediate comprising:a quadrate paper sheethaving top, bottom, and side edges, and first and second faces, said topand bottom edges substantially parallel to each other and said sideedges substantially parallel to each other; first and second fold linessubstantially parallel to said top and bottom edges and dividing saidsheet into first, second and third panels, said first panel between saidtop edge and said first fold line, and said second panel between saidfirst and second fold lines; said first and second panels each having afirst length along said side edges, and said third panel having a secondlength along said side edges; a cutout in said second panel; a patchhaving first and second faces, a central area approximately the size ofsaid cutout, and a peripheral area surrounding said central area; arelease coating provided on said first face of at least a significantpart of said central area of said patch; a first pressure sensitiveadhesive disposed between said peripheral area of said patch and one ofsaid faces of said second panel, and holding said patch to said secondpanel; a decal having first and second faces; indicia associated with atleast one of said decal faces; a second, permanent, pressure sensitiveadhesive associated with said decal second face, said second adhesiveengaging said release coating on said patch, and removable from saidpatch with said decal; and wherein said first pressure sensitiveadhesive is disposed between said peripheral area of said patch firstface and said second face of said second panel.
 11. A mailer typebusiness form intermediate as recited in claim 10 further comprisingoutgoing address indicia on said third panel first face.
 12. A mailertype business form intermediate as recited in claim 11 furthercomprising adhesive means for holding said intermediate in a mailerconfiguration when said paper sheet is folded about said first andsecond fold lines to form a mailer having said second panel sandwichedbetween said first and third panels; and said first face of said thirdpanel forming an outside face of the mailer and said decal and patchcovered by said first and third panels, and wherein said second lengthis less than said first length.
 13. A mailer type business formintermediate as recited in claim 12 wherein said adhesive meanscomprises a plurality of patterns of pressure activated cohesive.
 14. Amailer type business form comprising:a first solid paper panel; a secondpaper panel having a cutout therein and first and second faces; a thirdsolid paper panel; said second panel sandwiched between said first andsecond panels so that said cutout is covered by said first and secondpanels; adhesive means for holding said panels to each other with saidsecond panel sandwiched between said first and second panels; a patchhaving first and second faces, a central area approximately the size ofsaid cutout, and a peripheral area surrounding said central area; arelease coating provided on said first face of at least a significantpart of said central area of said patch; a first pressure sensitiveadhesive disposed between said peripheral area of said patch and one ofsaid faces of said second panel and holding said patch to said secondpanel; a decal having first and second faces; indicia associated with atleast one of said decal faces; a second, permanent, pressure sensitiveadhesive associated with said decal second face, said second adhesiveengaging said release coating on said patch, and removal from said patchwith said decal; and wherein said first pressure sensitive adhesive isdisposed between said peripheral area of said patch first face and saidsecond face of said second panel.
 15. A mailer type business form asrecited in claim 14 wherein said patch and decal mounted thereon have athickness; and wherein said thickness of said patch and decal is amaximum of 0.010 inches.
 16. A mailer type business form comprising:afirst solid paper panel; a second paper panel having a cutout thereinand first and second faces; a third solid paper panel; said second panelsandwiched between said first and second panels so that said cutout iscovered by said first and second panels; adhesive means for holding saidpanels to each other with said second panel sandwiched between saidfirst and second panels; a patch having first and second faces, acentral area approximately the size of said cutout, and a peripheralarea surrounding said central area; a release coating provided on saidfirst face of at least a significant part of said central area of saidpatch; a first pressure sensitive adhesive disposed between saidperipheral area of said patch and one of said faces of said second paneland holding said patch to said second panel; a decal having first andsecond faces; indicia associated with at least one of said decal faces;a second, permanent, pressure sensitive adhesive associated with saiddecal second face, said second adhesive engaging said release coating onsaid patch, and removal from said patch with said decal; and whereinsaid first adhesive is disposed between said patch second face and saidfirst face of said second panel, and wherein said patch is flexible anddimensioned with respect to said cutout so that when in a stack withother intermediates the patch and said decal thereon flex into saidcutout and the effective thickness of said patch and decal are thereonis substantially the same as the combined thickness of said secondpanel, first adhesive, and patch adjacent said cutout.